Kamco CF40 Evolution Safety & Operating Manual

Brand
Kamco
Model
CF40 Evolution
Type
Safety & Operating Manual

Kamco CF40 Evolution is a power flushing pump designed to clean and maintain central heating systems. It features a powerful motor and a large water tank, allowing for efficient flushing and removal of sludge and debris. With its flow reverser lever, you can easily change the direction of water flow to ensure thorough cleaning. The built-in dump valves enable quick and easy draining of dirty water, while the addition of flushing chemicals helps dissolve stubborn deposits.

Kamco CF40 Evolution is a power flushing pump designed to clean and maintain central heating systems. It features a powerful motor and a large water tank, allowing for efficient flushing and removal of sludge and debris. With its flow reverser lever, you can easily change the direction of water flow to ensure thorough cleaning. The built-in dump valves enable quick and easy draining of dirty water, while the addition of flushing chemicals helps dissolve stubborn deposits.

GENERAL SAFETY AND GUIDANCE
ELECTRICAL SAFETY GUIDANCE
OVERVIEW OF PUMP LAYOUT
230 volt models are tted with a 13 ampere plug and
may be operated from a standard 230 volt 13 ampere
power supply.
110 volt models must only be operated through a 110
volt transformer of the correct rating to avoid damage
to the motor.
Always use an RCD or plug the pump into a mains socket
protected with a built in RCD.
Switch the power ushing pump and the power supply off
before plugging into the mains electricity supply.
Always switch off the power ushing pump and isolate it
from the power supply when leaving it unattended.
Do not commence using this power ushing pump
until you have read these instructions fully. Ask for
clarication if you do not fully understand its use and
application.
It is the user’s responsibility to ensure that this pump
is suitable for the work to be carried out, and to wear
suitable personal protective equipment.
This pump weighs more than 10kg and should
only be lifted by the handle when empty.
Do not move or drag the pump by its power
cable or the hoses.
Central Heating
Power Flushing Pumps
CF40 Evolution & CF90 Quantum
CLEARFLOW CENTRAL HEATING POWER FLUSHING PUMPS - SAFETY & OPERATING GUIDE
Flow reverser
lever
ON/OFF switch
Fresh water
connection
Combined isolating
& dump valves
Flow & return
Motor
Tank
Dump hose
connection
Overow
connection
Carry handle
Combined isolating
& dump valves
Water inlet valve
Filler cap
Maximum level
Minimum level
Wheels
A power ush should only be carried out by a suitably trained
person familiar with all aspects of heating systems.
This pump may be used with any commercially available ushing
and descaling chemical.
Connect each hose to its connection point (see diagram), ensuring
that there is a seal in each brass hose connector. Turn the brass
connectors clockwise until hand tight.
The following is a brief guide to the procedure and may NOT
be correct for all systems.
Turn on the heating system and identify problem flow areas,
cold radiators, or those with cold spots, then switch the
system off. Make a note of the location of each radiator and its
condition.
Carefully record how many turns are required to shut off
the radiator and lock shield valves. This will enable you to
‘balance’ the system quickly once you have finished. Open all
valves fully (both ends of radiator).
Thermostatic radiator valves must be set to the fully open
position. Remove the heads and check that the plunger pin
moves freely. Check that diverter or zone valves are in the fully
open position, setting manually if necessary.
If an anti-gravity / check valve is present, this must be by-
passed or bridged to allow the flow reversing action to be
used. Tie up the ball cock or turn of the mains water supply by
another means.
Drain enough water from the system to empty the F&E tank.
This can be drained into the Clearflow tank once the pump is
connected.
You will need to either cap off, or loop together, the expansion
and cold feed pipes to avoid filling and overflowing the
expansion tank. Looping the feed and expansion pipes
together may enable them to be flushed during the cleansing
process if they are not close coupled in the heating system, or
connected via an air separator.
The hose between the two pipes should incorporate a valve
so that the circuit can be closed off when flushing individual
radiators and should be removed after the power flush.
Position the unit in a room with
a suitable drain point and a
mains water supply.
Set both isolation valves to the
closed position.
Run the drain hose and
overflow hose to a suitable
drain.
Connect the mains water supply
hose to a suitable fresh water supply. Open the orange valve
and fill the tank with water to a level between the Minimum
and Maximum marks.
The normal precautions during work on any heating system
should be taken, place a drip tray or waterproof groundsheet
underneath the pump and surrounding area.
Connect the flow and return hoses to the heating system at
the selected point.
Alternative options are:
Connection to the circulator pump fittings.......
Close the circulator pump isolating
valves. Remove the complete
pump. Screw the two 1.1/2” BSP
male ended hose adaptors on
to the end of the standard flow
and return hoses, and connect on to the circulator pump
isolating valves. Only open the isolating valves once the unit is
connected.
Connection onto radiator pipe ‘tails’...
Across the “tails” to a radiator (having drained and
disconnected this radiator) using appropriate 1/2” or 3/4” BSP
female adaptors to connect to the valve bodies. The radiator
valves should be closed to isolate the flushing pump from the
system until power flushing is commenced.
Connection to flow and return pipework to boiler...
Across the flow and return connections at the boiler isolating
the boiler itself.
Connection across cold feed and expansion pipes...
By connecting across the cold feed and expansion pipes when
not adjacent to each other in the same pipe run. Isolate the
water supply to the F&E tank prior to fitting.
First use the Clearflow pump alone to loosen and mobilise
sludge and debris into the fast moving system water, and
discharge the worst of the loose debris to waste. Only after
Preparation of heating system
Connecting the pump to heating system
Pump location and preparatory work
Flow &
return hoses
Dump
hose
Water inlet
hose
Overow
hose
Brass hose
connector
Combination Boiler Systems........
The above connection method is generally used when
power ushing a system with a combination boiler, when
the system circulator pump is located in the boiler casing,
and is difcult to access. Alternatively, use a Kamco CP2
pump head adaptor.
Additional advice relating to combination boiler
systems......
During powerushing, there is no circulation through the
secondary heat exchanger of combination boilers.
To minimise the possibility of debris being pushed into the
secondary heat exchanger circuit, close the boiler isolation valves
during this rst stage of the power ushing process.
GETTING STARTED
Power ushing procedure
Page 2
Vented systems
this stage is the chemical added so that it can then work
specifically to disturb, loosen and dissolve more stubborn
accumulations of debris.The chemical can then work
specifically to disturb, loosen, and dissolve more stubborn
accumulations of debris.
Either remove the tank filler cap or leave it loosely on the tank
neck if there is some splashing whilst flushing.
Set both valves in the closed position.
Plug the pump into a power supply and switch supply on.
The flow reverser lever has
two positions, LEFT, and
RIGHT.
If the lever is to the left, water
will flow into the heating
system through the left hand
side hose, and water will
return to the tank along the
right hand hose. Pushing the
lever to the right reverses the
direction of flow and return.
The exact direction of flow is not of any great importance until
you wish to ‘dump’ the system water.
Switch the pump on and make sure that the water level in the
tank remains at least 10 cm above the minimum mark, adding
more water if necessary.
Check all hoses and connections for leaks, and repair before
continuing.
Run the pump for ten minutes, reversing the direction of flow
regularly by moving the lever from left to right, and vice versa.
When ‘dumping’,
the water level
in the tank will
fall as dirty
water is diverted
down the drain,
and does not
return into the
pump tank.
Switch the pump
on and operate
the correct
dump valve
depending upon
the direction of
flow. If the flow
reverser lever
is to the left, twist the right-hand dump valve through 180
o
to show the word ‘dump’, ensuring that the left-hand valve
remains in the ‘circulation’ position.
If the flow reverser lever is to the right, twist the left-hand dump
valve through 180
o
to show the word ‘dump’, ensuring that the
right-hand valve remains in the ‘circulation’ position.
Open the orange water inlet valve and adjust to allow fresh
water to enter the tank at the same rate as water is exiting the
dump hose. Make sure that the tank water level remains at
least 10 cm above the minimum mark, and continue dumping
until the waste water runs relatively clear.
Turn the valve which is in ‘dump’ mode through 180
o
to restore
full circulation through the pump and the system. Close the
water supply inlet valve once the water level in the tank has
stabilised between minimum and maximum marks.
Bleed all radiators to expel any air.
This stage is carried out once the initial brief circulation and
discharge of the worst of the debris has been carried out.
Switch the pump on so that water is re-circulating through the
heating system. Remove the tank filler cap and carefully pour
either PowerFlush FX2 or Hyper-Flush liquid into the tank.
Keep the pump running for 15 minutes, regularly reversing the
direction of flow.
With the Clearflow pump still running, close all radiator valves
to enable the cylinder coil (if present) to be thoroughly flushed,
reversing the flow regularly.
Next close any diverter / zone valves to direct the flow through
the heating circuit, in preparation to flush each radiator.
Starting on the ground floor radiators, fully open both radiator
valves on the nearest radiator. Alternatively, start with the worst
radiator first, so that the strongest concentration of chemical is
directed at the worst areas of the system.
Flush the radiator, reversing the flow regularly until it is cleared.
Once cleared close both valves and move to the next radiator.
Open both radiator valves, and repeat the procedure.
Work through the remaining radiators in turn, until every
radiator in the system has been flushed individually.
Having flushed each radiator individually, then closed their
valves, set the pump into dumping mode. With only the last
radiator valves open, operate the pump until the water leaving
the dump hose is completely clear. Reverse the direction
of flow and the isolating / dump valves accordingly so that
dumping is performed in both directions.
Once the dumped water from both directions is clear, close
both radiator valves.
Repeat this process on each individual radiator until all have
been cleared.
If the system has a hot water cylinder, open the diverter valve
and flush the coil, dumping in both directions.
Finally, flush the boiler, dumping in both directions.
If you have used PowerFlush FX2 flushing liquid, which is
acidic, it must be neutralised to prevent long term corrosion.
Set the Clearflow pump to normal recirculation mode then
open all radiator and diverter valves. With the pump running,
add 100gm of Neutralising Crystals to the tank. If the water
foams, add a few drops of Foambreaker antifoam chemical.
Continue circulating in both directions for fifteen minutes, then
set to dump mode and dump for at least ten minutes to clear
all chemicals. Check the water leaving the dump hose with pH
paper. Continue dumping until the paper shows a pH of 7 or
the same pH reading as the property’s main water supply.
Set the Clearflow to normal re-circulation mode.
The heating system has now been fully flushed and is full of
fresh clean water. You should now add a good quality corrosion
inhibitor, such as SystemSafe-DM. First open the dump valve
to reduce the water level in the tank to 5cm (2”) above the
minimum line.
Flow
reverser
lever
Water
inlet
valve
Motor
switch
Page 3
Commencing the power ush
What happens when dumping
Addition of power ushing chemicals
Dumping the heating system water
Use of stronger power ushing chemicals
On completion of the power ush
Set the pump to normal re-circulation mode, then with the unit
running, add the corrosion inhibitor to the reservoir. Allow the
chemical to circulate through the system for about 10 minutes,
reversing direction occasionally.
Switch the pump off and unplug it from the power supply.
Disconnect all hoses from the pump and the heating system.
Empty the pump tank of any remaining water. If the system is
vented, the residual water (which may contain some corrosion
inhibitor) may be poured into a bucket and added to the F&E
tank after this has been cleaned.
Reconnect any removed radiator or disconnected boiler or
pump. Reset radiator valves to original settings. Remove any
temporary isolating valves or caps on expansion and cold feed
pipes, and restore non return valves to normal operation if
necessary. The feed and expansion tank should be thoroughly
cleaned and disinfected before placing into service again.
Page 4
Before you leave
Re-instating the system
6. Set Clearflow into circulation mode, with full flow
through whole heating system
(all radiator valves open).
Add Systemsafe-DM and
circulate for 10 minutes
before disconnecting Clearflow and restoring system
to normal operation. B
leed all radiators.
Now dump on the same radiator in the
opposite direction,until water runs clear. Close the
radiator trapping the fresh water.
5. Start dumping. Adjust inlet water to ensure tank
water level remains constant. Allow to run until
dump water is clear.
After circulating through last radiator,
switch to dumping on that one radiator,
until water runs clear.
4. Switch on Clearflow pump, and circulate for 10
minutes, reversing flow regularly.
Shut off first radiator, and move to second. Work
around system, putting full flow through
each radiator in turn.
Test that dump water is neutral
with either pH paper or electronic
pH meter.
3. Open all radiator and lock-shield valves, and set
zone valves to manual position, for full flow
hroughout system.
Shut off all radiator valves except for one radiator.
Allow full flow through this radiator for 5 minutes,
reversing flow regularly.
Commence final dump procedure,
with all radiators wide open. Allow
to run until dump water is clear.
2. Connect Clearflow pump into heating system.
Connect dump, water inlet, and overflow hoses to
Clearflow pump.
Continue circulation through wide open system for
fifteen minutes, reversing flow regularly.
Add 100gm of Neutralising
Crystals to tank, and circulate
for 10 minutes.
1. If system is vented, cap off the cold feed and
expansion pipe.
If possible, switch on boiler to heat water to 50
o
C.
Don’t leave boiler firing continuously.
Restore circulation through Clearflow pump
and complete heating system
(all radiator valves open).
7. Pour 2.5 litres
PowerFlush FX2
into Clearflow tank.
Open up previous radiator, and dump on that until
water runs clear. Work around system in reverse,
dumping through each individual radiator in turn.
7. Pour 500ml of
Hyper-Flush
into Clearflow tank.
EITHER.
EITHER.
When using
FX2
When using
Hyper- Flush
Quick guide to the power flushing procedure
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Kamco CF40 Evolution Safety & Operating Manual

Brand
Kamco
Model
CF40 Evolution
Type
Safety & Operating Manual

Kamco CF40 Evolution is a power flushing pump designed to clean and maintain central heating systems. It features a powerful motor and a large water tank, allowing for efficient flushing and removal of sludge and debris. With its flow reverser lever, you can easily change the direction of water flow to ensure thorough cleaning. The built-in dump valves enable quick and easy draining of dirty water, while the addition of flushing chemicals helps dissolve stubborn deposits.

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